Structure mountable assembly

ABSTRACT

A modular tool assembly including a tool base configured to releasably secure a modular tool arrangement in a fixed relationship relative to a mounting surface. The tool base includes an upper housing portion and a lower housing portion having a mounting seal extending therefrom. The mounting seal cooperates with the mounting surface to define a vacuum pocket therebetween. A vacuum generating mechanism is configured to remove air from the vacuum pocket through an aperture in the lower housing portion. A modular tool attachment releasably engages a portion of the tool base to secure the modular tool attachment to the tool base. The modular tool attachment can include a self leveling laser leveling device having a laser light source mounted within a housing to project an alignment beam through an opening in the housing to denote a reference plane along the mounting surface.

This application is a continuation of U.S. Ser. No. 10/919,708 filedAug. 17, 2004 and a continuation of U.S. Ser. No. 10/977,503 filed Oct.29, 2004, which is a continuation-in-part of U.S. Ser. No. 10/919,569filed Aug. 17, 2004, the entire contents of each are incorporated hereinby reference.

BACKGROUND

This invention relates to a modular assembly having a base incorporatinga mounting arrangement for securing a modular tool assembly to amounting surface.

Suction mounting devices are frequently coupled to tools utilized fortransporting materials between locations or attaching devices tosurfaces. Battery powered suction devices are typically used in theconstruction and assembly industries. For example, auto workersfrequently use hand held suction devices to manipulate panes ofautomotive glass between assembly locations.

Therefore, it is desirable to provide a modular assembly having a baseincorporating a vacuum mounting arrangement that is configurable tosupport a tool assembly including a variety of tools, such as hooks,clamps, light sources, battery powered tools, laser leveling devices andsimilar devices. It is also desirable to provide a modular assemblyhaving a vacuum mounting arrangement that can be easily mounted to amounting surface without damaging the finish of the surface. It isfurther desirable to provide a monitor to monitor the vacuum seal toensure proper securement of the assembly to the mounting surface.

Recently, power tool manufacturers have developed common batteryarrangements that support a variety of power tools sold in a combinationpackage. Such kits may include tools such as drills, saws, andflashlights. Manufacturers are interested in adding laser alignmentproducts, such as laser levels to these kits. Laser levels have replacedchalk lines and torpedo levels as the preferred tool for creating anddisplaying a level line on a surface. These tools are commonly used forinterior decorating projects, such as hanging pictures and installingcabinetry, and exterior projects, such as brick laying and deckassembly.

Laser levels are easy to set up and generate an alignment beam whichdoes not mark up the mounting surface. Current laser level products areeither mounted to an adjustable frame or are secured to a mountingsurface with a fastener. Laser levels typically include a laser lightsource mounted within a housing. One limitation of current laseralignment devices is that the laser level cannot be easily repositionedon surfaces once mounted. Many laser level devices either incorporate apin or a fastener to mount the level on a vertical surface to generatethe alignment line. If the laser level is not properly aligned on thewall, a user will have to remove the device and remount in the properposition, placing additional marks and holes on the surface which mustbe patched.

BRIEF SUMMARY

Accordingly, the present invention provides a modular tool assemblyhaving a vacuum mounting arrangement for securing the assembly to amounting surface. The modular tool assembly includes a base having upperand lower housing portions. A mounting seal extending from a lowerportion of the housing cooperates with the mounting surface to define asuction mounting area therebetween. An upper housing portion may includea guide member having one or more receiving portions formed therein.Alternatively, the housing portion may be provided with a mountingelement to mate with a complementary mounting element of a modular toolattachment.

A vacuum generating mechanism is disposed within the assembly, forexample in the upper housing portion (although it could be provided inthe lower housing portion). In one embodiment, the vacuum generatingmechanism is electrically connected to a power source (which may includea rechargeable power source). In this embodiment, the vacuum generatingmechanism includes a motor and a pump operatively driven by the motorand configured to remove air from the suction mounting area. In oneaspect, the air may be removed through an aperture in the lower portionof the tool base to secure the housing to the mounting surface. A sensormay be mounted proximate an aperture in the lower housing portion of thetool base. The sensor monitors the suction mounting area and activatesthe pump if the sensor detects a loss of pressure in the suctionmounting area.

A switch that may be disposed on the upper portion of the tool basehousing or elsewhere is operatively connected to the vacuum generatingmechanism allows a user to activate the vacuum generating mechanism. Atleast one electrical connector may be provided in, for example, a topsurface of the upper portion of the tool base housing to electricallyconnect the power source to a modular tool attachment.

A modular tool is releasably secured to a portion of the housing of thetool base. The modular tool may include a modular tool attachment thatcan be mounted on the base in a fixed relationship relative to themounting surface. The modular tool attachment may include one or moreprojections extending from a tool attachment housing that releasablyengages one or more receiving portions in a portion of the tool base.Alternatively, the tool attachment housing may have a complementarymounting element that cooperates with a mounting element provided on thehousing to releasably secure the tool attachment housing to the base.

In one aspect of the present invention, the vacuum generating mechanismincludes a manually operable pump cooperating with the suction mountingarea to remove air from the suction mounting area. In one aspect, theair may be removed through an aperture in the housing to secure the baseto the mounting surface. In an alternative embodiment the vacuumgenerating mechanism includes a lever to actuate a vacuum pad and createan air pocket or suction between the device and the surface on which thedevice is mounted.

In another aspect of the invention, the modular tool comprises a laserleveling device having a housing, a laser light source disposed withinthe housing operatively connected to a power source, the laser lightsource including at least one diode projecting an alignment beam throughan aperture in the housing to denote a reference plane along themounting surface. One or more bubble levels or other devices forindicating level may be provided on the laser level housing. The modulartool may also comprise a flashlight, a clamp, a tape measure or othermeasuring device, a tool holder (such as a driver bit holder), analignment device, a hook, powered (including battery powered) andnon-powered tools.

Alternatively, the assembly can be in the form of a laser levelingdevice having a suction mounting arrangement that comprises a housingand a mounting seal extending from the lower portion of the housing. Themounting seal extends around a cavity in the lower portion of thehousing and cooperates with an attachment surface to define a suctionmounting area therebetween. A power source is provided within thehousing. In one aspect of the present invention, the power sourcecomprises a removably mounted battery or power cell. In another aspectof the invention, the power source is a rechargeable power cell securelymounted within the housing.

The laser leveling device includes a suction mounting arrangementconfigured to secure the laser leveling device to an attachment surface.A first aspect of the suction mounting arrangement includes a vacuumgenerating mechanism disposed within the laser level housing whichevacuates air from the suction mounting area. The vacuum generatingmechanism includes a motor connected to the power source and a pumpoperatively driven by the motor. A sensor disposed proximate the cavitymonitors the vacuum seal in the suction mounting area and activates thepump if the sensor detects a loss of pressure. The pump is configured toremove air from the suction mounting area through an aperture in thecavity to ensure the laser level housing is secured to the attachmentsurface.

A second aspect of the suction mounting arrangement for the laserleveling device includes a manually operable pump cooperating with thesuction mounting arrangement to secure the laser level to an attachmentsurface. The suction mounting arrangement comprises a manually operablepump cooperating with the mounting seal and configured to remove airfrom the suction mounting area through an aperture in the housing tosecure the housing to the attachment surface.

A third aspect of the suction mounting arrangement includes a lever toactuate a vacuum pad and create an air pocket or suction between thedevice and the surface on which the device is mounted.

A laser light source is mounted within the housing in a fixedrelationship relative to the attachment surface and is operativelyconnected to the power source. The laser light source includes at leastone diode projecting an alignment beam through an opening in the housingto denote a reference plane along the attachment surface. A lens ismounted in an end wall of the housing and cooperates with the at leastone diode to project an alignment beam along the attachment surface.

In one aspect of the invention, the laser light source includes a pairof opposing diodes positioned in a coplanar relationship which projectalignment beams through opposing end walls of the laser level housing.In another aspect of the invention, the laser light source comprises afirst diode projecting a first alignment beam through an opening in theend wall of the housing and a second diode projecting a second alignmentbeam generally perpendicular to the first alignment beam through anopening in a side wall of the housing.

The laser level housing includes a handle formed in a top portion of thehousing. A pump actuation switch is provided on a side wall of thehousing adjacent the handle. The pump actuation switch cooperates withthe vacuum generating mechanism or manual pump when the laser level ispositioned on the attachment surface to evacuate air from the suctionmounting area. A switch extends through the housing allowing a user toactivate the laser light source when the laser level is mounted to theattachment surface.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view of the modular tool assemblyhaving a modular tool attachment releasably secured to a tool base inaccordance with the present invention;

FIG. 2 is a perspective view of the tool base of the modular toolassembly in accordance with the present invention;

FIG. 3 is a cross-sectional view of the tool base along line 3-3 of FIG.2;

FIG. 4 a is a perspective view of the laser leveling modular toolattachment configured for coupling to the modular tool assembly;

FIG. 4 b is a perspective view of a flashlight modular tool attachmentconfigured for coupling to the modular tool assembly; and

FIG. 4 c is a perspective view of a clamp modular tool attachmentconfigured for coupling to the modular tool assembly.

FIG. 5 is a perspective view of one embodiment of the modular toolassembly having a modular tool attachment wherein the modular toolassembly has a manually operable vacuum attachment.

FIG. 6 is a perspective view of an embodiment similar to that shown inFIG. 5 except that the manual pump is shown in a different location.

FIG. 7 is a perspective view of one embodiment of a modular toolassembly having a manually operable vacuum attachment.

FIG. 8 is a perspective view of the manually operable vacuum attachmentfor use with the assembly of FIG. 7 and with the modular tool assemblyand the base removed.

FIG. 9 is a side perspective view of the manually operable vacuumattachment for use with the assembly of FIG. 7, with the modular toolassembly removed, and schematically showing operation of the lever andthe vacuum pad.

FIG. 10 illustrates a laser leveling device incorporating a vacuummounting arrangement in accordance with the present invention;

FIG. 11 is a bottom perspective view of the laser level of the presentinvention;

FIG. 12 is a side elevation cross-sectional view of the laser levelingdevice incorporating one aspect of a suction mounting arrangement alongline 12-12 of FIG. 10;

FIG. 13 is a fragmentary perspective illustrating a second aspect of thesuction mounting arrangement of the laser leveling device of the presentinvention;

FIG. 14 is a perspective view of the second aspect of the suctionmounting arrangement of the laser leveling device of the presentinvention;

FIG. 15 is a cross-sectional view illustrating another aspect of thelaser level generator of the laser leveling device of the presentinvention; and

FIG. 16 is a side plan view illustrating a second embodiment of thelaser leveling device of the present invention.

FIG. 17 is a perspective view of another embodiment of modular toolassembly of the present invention having a laser generator housing.

FIG. 18 is a front view of the tool assembly of FIG. 17 with the lasergenerator housing pivoted in a forward position and with internaldetails of the base being visible.

FIG. 19 is a rear view of the tool assembly of FIG. 17.

FIG. 20 is a side view of the tool assembly of FIG. 18 with internaldetails being visible.

FIG. 21 is a perspective view of the tool assembly of FIG. 17 in oneposition and with internal details being visible.

FIG. 22 is a cut-away portion of the laser generator housing of FIG. 17to show details of the self-leveling mechanism according to oneembodiment of the present invention.

FIG. 23 shows several parts of the self-leveling mechanism of FIG. 22.

FIG. 24 shows the self-leveling mechanism of FIG. 22.

FIG. 25 shows another embodiment of a self-leveling mechanism that canbe used in the laser generator housing.

FIG. 26 shows the self-leveling mechanism of FIG. 25 with certainfeatures shown in exploded view.

FIG. 27 is another embodiment of a self-leveling mechanism.

DESCRIPTION

Referring now to FIGS. 1 and 2, a modular tool assembly 10 configurableto releasably secure a variety of portable tools, including powered andnon-powered tools, is disclosed. Modular tool assembly 10 includes atool base 12 incorporating a vacuum mounting arrangement for securingthe tool base 12 and a removably mounted modular tool attachment 14 to amounting surface 16. Tool base 12 includes a housing 18 having a lowerportion 20 and an upper portion 22. A suction cup or mounting seal 24extends from the lower housing portion 20.

A guide member 26 extends generally vertically from the lower housingportion 20 to provide an outer mounting guide for modular toolattachment 14. One or more receiving portions 28 are formed in the guidemember 26 to receive and secure one or more connecting arms orprojections 30 extending from the modular tool attachment 14. The guidemember 26 cooperates with the tool housing 32 of the modular toolattachment 14 to position and secure the tool attachment 14 on the toolbase 12.

Referring now to FIGS. 1 and 4 a, the modular tool attachment is a laserleveling device 34 adapted for attachment to the modular tool base 12. Alaser light source (not shown) is mounted with the housing 32. The laserlight source includes at least one diode (not shown) which projects oneor more alignment beams 36 through an opening 38 in an end wall 40 ofthe housing 32. In one aspect of the present invention, a lens 42 isprovided in the opening 38 to cooperate with at least one diode to focusthe alignment beam 36. However, it is understood that the alignment beam36 may project through a standard opening in the housing 32 to denote areference plane along the mounting surface 16.

In one aspect of the present invention, the laser light source isrotatably mounted within the housing 32 to allow a user to adjust theposition of the laser light source once the laser level attachment 34 isplaced in a fixed relationship to the mounting surface 16 when mountedon the tool base 12. It is understood, however, that the laser lightsource may be fixedly mounted to a portion of the housing. It is alsocontemplated that the attachment 34 be mounted to the modular tool base12 in a manner that allows the attachment 34 to be selectively pivotedwith respect to the tool base. Desirably, the attachment 34 can beselectively pivoted in a manner such that the projected beam can be at aselected angle from the vertical or horizontal.

It is also contemplated that laser level attachment may include a laserlight source having a pair of diodes in a coplanar relationship whichproject alignment beams through openings in opposing end walls of thelaser level housing. Further, the laser light source may include a firstdiode which projects a first alignment beam through a first opening inthe end or side wall of the housing and a second diode projecting asecond alignment beam generally perpendicular to the first alignmentbeam through a second opening in an end or side wall of the housing.

One or more bubble levels 44 can be provided such as along the topportion 46 of the laser leveling device housing 32. The bubble levels44, 48 assist the operator in positioning the laser level attachment 34mounted on the tool base 12 to the mounting surface 16 to ensure thatthe alignment beam 36 projects across the surface 16 at the desiredangle. In one aspect of the invention shown in FIG. 4 a, a pair ofbubble levels 44, 48 are provided on the top portion 46 of the laserlevel housing 32 to provide both horizontal and vertical alignmentinformation to the operator prior to securement of tool assembly 10 tomounting surface 16. It is understood that a single bubble leveldisposed on the laser level housing may also be used to display thealignment position of the modular tool assembly.

Referring now to FIGS. 2 and 3, a vacuum generating mechanism 50 isdisposed within the tool base 12 to create a suction effect to securethe tool base 12 to the mounting surface 16. In one embodiment, thevacuum generating mechanism 50 includes a motor 52 and a vacuum pump 54operatively connected to the motor 52 disposed within the upper housingportion 22. It is understood that the motor 52 and the pump 54 may beformed as a single unit. A hose 56 connects an inlet 58 on the pump 54to an aperture 60 in the bottom surface 62 of the lower housing portion20. Air is drawn through the aperture 60 by the pump 54.

A power source 64 disposed within the upper housing portion 22 iselectrically connected to the motor 52. The power source 64 may includea rechargeable battery pack, such as a lithium ion or nickel cadmiumbattery, or removable rechargeable or alkaline battery. In one aspect ofthe present invention, one or more electrical contacts 66 in electricalcommunication with the power source 64 extend through a top surface 68of the upper housing portion 22 to supply power to the modular toolattachment 14. It is also contemplated that the modular tool attachment14 may include an independent power source.

The motor 52 and the pump 54 of the vacuum generating mechanism 50cooperate with the mounting seal 24 to create a vacuum pocket or suctionmounting area 70 between the mounting surface 16, the mounting seal 24,and the bottom surface 62 of the lower housing portion 20 of the toolbase 12.

The mounting seal 24 is preferably a rubber suction cup that cooperateswith the mounting surface 16 to define a vacuum pocket 70 therebetween.In one aspect of the present invention, the bottom surface 62 of thelower housing portion 20 is arcuately shaped to form a cavitycooperating with the mounting seal 24 and the mounting surface 16 toenhance the suction effect created in the vacuum pocket 70. In thisaspect, the modular tool attachment 14 and, in particular, the mountingseal 24, is placed into contact with a mounting surface 16 and pressedagainst the mounting surface to evaluate air from the vacuum pocket 70.

In another aspect of the present invention, air is removed from thevacuum pocket 70 by a pump. In one alternative, a switch 72 disposed onthe upper housing portion 22 is operatively connected to the pump 54 toallow a user to activate the pump 54 to remove air from the vacuumpocket 70. The switch 72 may also control electrical contacts 66supplying power to a device in the modular tool attachment 14, therebycontrolling the activation of both the pump 54 of the vacuum generatingmechanism 50 and the modular tool attachment 14. Alternatively, themodular tool attachment 14 may incorporate a switch that willindependently operate the modular tool attachment.

Once the user places the mounting seal 24 of the tool base 12 in contactwith a mounting surface 16, the user actuates the switch 72, whichactivates the pump 54. The pump 54 evacuates air from the vacuum pocket70 through the inlet 60. A sensor 74 disposed in the bottom surface 62of the lower housing portion 20 monitors the vacuum pocket 70. Thesensor 74 activates the pump 54 to remove air from the vacuum pocket 70if the sensor detects a loss of pressure in the vacuum pocket 70. Lossof vacuum pressure may be caused by imperfections in the mountingsurface 16 or the seal 24 such as gaps or cracks that limit theeffectiveness of the mounting seal 24. The sensor 74 allows the pump 54to compensate for the surface flaws to ensure a proper seal between thetool base 12 and the mounting surface 16.

A third aspect of the vacuum generating mechanism includes a manuallyoperable pump cooperating with the mounting seal 24 to remove air fromthe vacuum pocket 70. A switch 72 a may be placed on either the lowerportion 20 or the upper portion 22 of the tool base as shown in FIGS. 5and 6. The switch 72 a may simply function to evacuate air from thevacuum pocket 70 when activated, such as by depressing the switch.Alternatively, the switch 72 a may operate the pump such that when theswitch 72 a is depressed, air is evacuated from the vacuum pocket.

Referring now to FIG. 4 b, a second modular tool attachment isdisclosed. In this instance, the modular tool attachment comprises aflashlight 76 having a flashlight head 78 and a flashlight body 80configured for securement to the tool base 12. The flashlight body 80includes a handle 82 formed in a top surface 84 of the body 80. One ormore connecting arms 86 extend from the flashlight body 80 to releasablyengage one or more receiving portions 28 in the guide member 26 of thetool base 12. Alternatively, the upper portion 22 such as the topsurface 60 or elsewhere may be provided with a mounting element toengage a complementary mounting element on the flashlight body 80. Forexample, the mounting element may include a magnetic surface, a hook, ora complementary portion of a hook-and-loop type fastener, mating ribs,and other mounting elements well known in the art. The flashlight head78 includes a shroud 88, a reflector 90 and a lens 92 mounted adjacent abulb (not shown). The vacuum generating mechanism incorporated in thetool base 12 allows hands-free use of the flashlight 76 when mounted ona mounting surface 16.

Referring now to FIG. 4 c, a third modular tool attachment for themodular tool assembly of the present invention is disclosed. The thirdmodular tool attachment comprises a clamp 94 having a handle 96pivotally attached to a clamp housing 98. The handle 96 includes adistal end forming a handle portion 100 to be grasped by a user and anopposed gripping portion 102 including an elongate jaw 104 providedthereon. The handle 96 pivots about a spring biased mount 106 disposedin the clamp housing 98. The clamp housing 98 includes a generallyhorizontal jaw 108 cooperating with a jaw 104 on the handle 96 to securea workpiece therebetween. The clamp housing 98 includes one or moreprojections 110 that releasably engage one or more receiving portions inguide member 26 of tool base 12. As with the flashlight 76, the clamphousing 98 may be mounted to the upper portion 22 by engagement with amounting element provided on the upper portion 22.

Referring now to FIGS. 1 and 4 a-4 c, a switch 112 provided in a wall of114 of the respective modular tool attachment embodiments may cooperatewith a switch 72 on the modular tool base 12 to activate the pump 54 ofvacuum generating mechanism 50 to mount the modular tool base 10 to themounting surface 16. As described above, it is understood that theswitch 72 may activate the laser light source of laser leveling device34, the bulb of flashlight head 78 of flashlight 76, or to activateanother modular tool attachment. Alternatively, the switch 112 may onlyactivate the vacuum generating mechanism 50 while an independent switchoperates the features of the modular tool attachments.

Referring now to FIGS. 7-9, another embodiment of the device of thepresent invention having a manual suction mounting arrangement is shown.In this embodiment, the base 12 having a mounting seal 16 is asdescribed above with other alternative embodiments. The mounting seal 16is provided with a top surface 200, a bottom surface 202 and a wall 204extending from the top surface 200 to contact the attachment surface 16and form a seal, as will be described below.

A lifting mechanism 210 provided on the top surface 200 of the mountingseal cooperates with the bottom surface 202 such that actuation of thelifting mechanism 210 lifts the bottom surface 202 to create a cavity70. The lifting mechanism 210 can be provided with a lever 212 thatextends from a portion of the tool base 12 such that movement of thelever 212 actuates the lifting mechanism 210. As shown in FIGS. 7-9, thelever 212 is rotated from a first position to a second position (counterclockwise direction) such that in the first position, there is nosuction and in the second position there is a suction or vacuum when thecavity 70 is created.

Desirably, the lever 212 is fixed in either the first or the secondposition until manually moved to the other position. As shown in FIG. 8,the lifting mechanism 210 may include a cam 220 operatively connected tothe bottom surface 202 such that rotation of the lever 212 causes thecam 220 and thus the bottom surface 202 to move toward the top surface200 and thereby create a cavity 70.

Turning now to FIGS. 10-16, the tool assembly of the present inventionprovides a laser leveling device 310 having a suction mountingarrangement for securing the device 310 to an attachment surface 312.The laser level 310 includes a housing 314 having a suction cup ormounting seal 316 provided on a lower portion 318 of the housing 314.FIGS. 10-12 illustrate a single piece housing 314. It is understood thata two-piece housing as illustrated in FIG. 16 may also be used toaccomplish the same objective. A cavity 320 is formed in the lowerportion 318 of housing 314. The suction cup or mounting seal 316 ispreferably a rubber seal that extends from a lower portion of thehousing 314 about the cavity 320. Other elastomeric materials may beused to accomplish the objective of being deformable to provide a seal.The suction cup 316 cooperates with the attachment surface 312 and thecavity 320 in the housing 314 to define a suction mounting area 322therebetween.

Referring now to FIG. 12, a first aspect of a suction mountingarrangement cooperating with the laser leveling device 310 in accordancewith the present invention is disclosed. The laser level 310 includes avacuum generating mechanism 324 that cooperates with a mounting seal 316to create a vacuum in the suction mounting area 322. The vacuumgenerating mechanism includes a motor 325 disposed within the laserlevel housing 314. A vacuum pump 326 operatively connected to the motor325 is mounted adjacent the motor 325 in the housing 314. It is alsounderstood that the motor 325 and the pump 326 may be assembled as asingle unit. A hose 328 connects an inlet 330 on the pump 326 to anaperture 332 of the cavity 320. The pump 326 cooperates with themounting seal 316 to create a vacuum between attachment surface 312 andcavity 320 to mount the laser level 310 in a fixed relationship relativeto attachment surface 312.

A laser light source 334 for generating an alignment beam 336 is mountedwithin housing. The laser light source 334 is rotatably mounted toeither an inner wall of the housing or a pivot 331 mounted on the vacuumgenerating mechanism 324 to allow a user to adjust the position of thelaser light source 334 once laser level housing 314 is secured to theattachment surface 312. The laser light source 334 may also be mountedto an inner wall of the laser level housing or fixedly mounted to aportion of vacuum generating mechanism.

The laser light source 334 includes at least one diode 333 that projectsan alignment beam 336 through an opening 338 in an end wall 340 of thelaser level housing 314. In one aspect of the present invention, a lens342 is provided in the opening 338 that cooperates with at least onediode 333 to focus an alignment beam 336. It is understood that thealignment beam 336 may project through a standard opening in the housing314 to denote a reference plane along the attachment surface 312.

A laser light source activation switch 344 extends through an elongatechannel 346 of the housing 314. A power source 348 disposed in laserlevel housing 314 powers both the motor 325 and the laser light source334. In one aspect of the present invention, the power source 348 is arechargeable battery pack, such as a lithium ion or nickel cadmium powercell securely mounted within housing 314. Alternatively, the powersource 348 is a removable alkaline battery.

Referring now to FIGS. 10 and 12, the laser level 310 includes a handleportion 350 formed into a top surface 352 of the housing 314. One ormore bubble levels 354 extend along the top portion 352 of the laserlevel housing 314. Bubble levels 354 assist the operator in positioningthe laser level 310 on the attachment surface 312 to ensure thatalignment beam 336 projects across surface 312 at the desired angle. Inone aspect of the invention shown in FIG. 12, a single bubble level 354displays the alignment position of the level 310 of surface 312. Inanother aspect of the laser leveling device 356 shown in FIG. 16, a pairof bubble levels 358, 360 are provided on the top portion 362 of laserlevel housing 364 to provide both horizontal and vertical alignmentinformation to the operator prior to securement of the laser level 356to surface 312.

One aspect of the suction mounting arrangement of laser leveling deviceincludes a pump actuation switch 366 that may be provided adjacenthandle 350 and is operatively connected to the pump 326. The useractuates switch 366 when the mounting seal 316 is placed in contact withattachment surface 312, allowing the pump 326 to evacuate air from thesuction mounting area 322 created between the attachment surface 312,the seal 316 and the cavity 320 through the aperture 332.

A sensor 368 provided proximate the cavity 320 monitors the pressure inthe suction mounting area 322. The sensor 368 activates the pump 326 toremove air from the suction mounting area 322 when the sensor detects aloss of vacuum pressure in the area 322 between the mounting seal 316and the attachment surface 312. Loss of vacuum pressure in the suctionmounting area 322 may be caused by imperfections in the attachmentsurface 312, such as gaps or cracks that limit the effectiveness ofmounting seal 316. The sensor 368 allows the pump 326 to compensate forthe surface flaws to ensure a proper seal between the laser level 310and the attachment surface 312.

Referring now to FIGS. 13 and 14, a second aspect of the suctionmounting arrangement cooperating with the laser leveling device 310 ofthe present invention. The laser light source 334 is rotatably mountedto an inner wall of the laser level housing 314 to allow a user toadjust the position of the laser light source 334 once the laser levelhousing 314 is secured to an attachment surface 312 and to project analignment beam through the lens 342 onto a surface.

A laser light source activation switch 370 extends through an elongatechannel 372 of the housing 314. A power source 348 disposed in the laserlevel housing 314 powers laser light source 334. A suction cup ormounting seal 374 extends from a lower portion 376 of laser levelhousing 314. It is understood that the suction cup 374 can be formed ina variety of geometries to accommodate various housing shapes. Themounting seal 374 cooperates with the attachment surface 312 to define asuction mounting area 322 therebetween.

A pump 378 is operatively connected to an aperture (not shown) in thelower portion 376 of housing 314. The pump 378 cooperates with themounting seal 374 to create a vacuum between the attachment surface 312and the lower portion 376 of laser level housing 314 to create a suctionmounting area 322. A pump actuation switch 380 is operatively connectedto the pump 378 adjacent the lower portion 376 of the housing 314 andthe mounting seal 374. A user actuates the switch 380 after the mountingseal 374 is placed in contact with the attachment surface 312, allowingthe pump 378 to evacuate air from the suction mounting area 322 if theuser detects a loss of vacuum pressure in the area 322. It is understoodthat the switch 380 may be provided in either a vertical or horizontalorientation on the laser level housing 314.

FIG. 15 illustrates another type of laser light source incorporated inthe laser leveling device 310 of the present invention. The laser level310 includes a laser light source 382 having a pair of diodes 384 in acoplanar relationship that project alignment beams 386 through openings338 in the end walls 340 of the laser level housing 314. It is alsocontemplated that laser light source may include a first diode whichprojects a first alignment beam through a first opening in the end orside wall of the housing and a second diode projecting a secondalignment beam generally perpendicular to the first alignment beamthrough a second opening in an end or side wall of the housing.

Referring now to FIG. 16, a second embodiment of a laser leveling devicehaving a vacuum mounting arrangement of the present invention isdisclosed. The laser level 356 comprises a lower housing 363 having arubber mounting seal 388 extending from a lower portion of housing 363and a pivotally mounted upper housing 364 enclosing a laser light sourcegenerating an alignment beam 390. The upper housing 364 pivots relativeto the lower housing 363 about a mount 392. The mount 392 includesdetents (not shown) that allow a user to position the upper housing 364at discrete angular increments, for example, 15° angle increments,relative to the lower housing 363, thereby allowing a user to rapidlyreposition the laser light source in the upper housing 364 when thelaser level 356 is secured to the attachment surface 394.

It is to be understood that any of the assemblies shown in FIGS. 10-16and described above can be provided with a manual suction mountingarrangement as shown in FIGS. 7-9 and described above. For example, thehousing 14, 314 can be provided with a mounting seal 16 as describedabove with other alternative embodiments. The mounting seal 16 isprovided with a top surface 200, a bottom surface 202 and a wall 204extending from the top surface 200 to contact the attachment surface 12and form a seal, as will be described below.

A lifting mechanism 210 provided on the top surface 200 of the mountingseal cooperates with the bottom surface 202 such that actuation of thelifting mechanism 210 lifts the bottom surface 202 to create a cavity20. The lifting mechanism 210 can be provided with a lever 212 thatextends from a portion of the housing 14 such that movement of the lever212 actuates the lifting mechanism 210. As shown in FIGS. 8-10, thelever 212 is rotated from a first position to a second position (counterclockwise direction) such that in the first position, there is nosuction and in the second position there is a suction or vacuum when thecavity 20 is created.

Desirably, the lever 212 is fixed in either the first or the secondposition until manually moved to the other position. As shown in FIG. 9,the lifting mechanism 210 may include a cam 220 operatively connected tothe bottom surface 202 such that rotation of the lever 212 causes thecam 220 and thus the bottom surface 202 to move toward the top surface200 and thereby create a cavity 20.

Turning now to FIGS. 17-21, another embodiment of the inventive modularassembly described above. In this embodiment, the tool attachment is alaser light generator that is self-leveling to provide a desiredhorizontal or vertical line. Other advantages and features will becomeapparent from the following description.

The embodiment shown in FIGS. 17-21 has a base 12 upon which aself-leveling laser generator housing 1030 is mounted. The base 12includes a vacuum generating mechanism for securing the base 12 asdescribed above. The base may be formed from three sections: a top 1002,a bottom 1004, and a rear 1006. A longitudinal axis 1008 of the baseextends through the top 1002 to the bottom 1004.

The top of the base 1002 may be slidably moveable with respect to thebottom 1004 to adjust the height of the generator housing 1030 withrespect to the bottom 1004. A rotating member 1010 is provided in thebottom 1004 accessible to the user to allow the user to move therotating member 1010 to cause the top 1002 to move up or down withrespect to the bottom 1004. As seen in FIG. 18, the rotating member 1010is connected to a screw 1012 upon which the top of the housing 1004 ismounted such that rotation of the rotating member 1010 causes the top1004 to move up or down depending on the direction that the rotatingmember 1010 is rotated.

As noted above the self leveling laser generator housing 1030 is mountedto the top 1002 of the base. FIG. 17 shows the generator housing 1030 inan upright position. In this position, when the base 12 is mounted to asurface such as a wall, the longitudinal axis 1032 of the generatorhousing 1030 is parallel to the plane of the wall (perpendicular to thelongitudinal axis 1008 of the base). When the generator housing 1030 isin this position, it can be rotated relative to the base 12 such thatthe generator housing longitudinal axis 1032 will be perpendicular tothe surface upon which the base 12 is mounted with the vacuum generatingmechanism 50 (as well as being perpendicular to the longitudinal axis ofthe base). The generator housing 1030 can also be pivoted forwardly withrespect to the base 12 so that the generator housing 1030 has a positionas shown in FIG. 18. While in this position, the generator housing 1030can be rotated such that the longitudinal axis 1032 of the generatorhousing is parallel to the longtidunal axis 1008 of the base 12.

The laser generator housing 1030 has a top 1034, front 1036, rear 1038,two side ends 1040, 1042, and bottom 1044 that is rotatably connected toa pivoting member 1046 having a sphere-like structure with its sides andtop truncated to fit the base 12 and generator housing 1030respectively. The pivoting member 1046 is movably secured to the top ofthe base 1002 to permit the laser generator housing 1030 to pivot withrespect to the base 12 as described above. The generator housing 1030 isselectively pivotable with respect to the base 12 to many differentpositions due to the frictional fit between the laser generator housing1030 and the base 12. Alternatively or in conjunction with thefrictional fit, the pivoting member 46 or a portion of the top 1034 ofthe base may be provided with a detent arrangement 1048 at selectedpositions to provide a plurality of positive stops when the lasergenerator housing 1030 is pivoted to a selected location.

As will be appreciated from the description below, the self-levelingfeature of this embodiment is effective when the laser generator housing1030 is in an upright position, as shown in FIG. 17. In that regard, oneembodiment of the self-leveling aspect is shown in FIGS. 22-24.

FIG. 22 shows a cut-away portion of the laser generator housing 1030from which it can be seen that the self-leveling mechanism 1100 includesa frame 1102, a rocking block seat 1140, a bearing rocking block 1150,and bearing straps 1170. The frame 1108 is in the shape of a T, wherethe vertical portion or shaft 1104 acts as the arm of a pendulum. Toprovide quicker self-leveling, the distal end of the vertical portion1104 of the frame may act as a counterweight 1106 or may be providedwith a counterweight (not shown).

The horizontal portion 1120 of the frame 1102 defines arms 1122 that areconfigured to hold a laser diode 1130 such that the light projected fromeach extends in a direction opposite from the other. The distal ends ofthe arms 1124, 1126 may also support a lens holder 1132 that supports alens 1134 through which the laser light emitted from the diode 1130passes. Desirably, each lens 1134 is rotatable with respect to the diode1130 so that the emitted beam can be adjusted to a variety of differentdirections such as horizontal, vertical, or positions between horizontaland vertical. The lens holder 1132 may be provided with indications sothat the movement in a particular direction can be indicated. Forexample, the indications may provide an indication of angular movementin degrees such as 5 degrees, etc.

Because each arm 1122 may support a laser diode 1130, the projected beammay differ from one end to the other. For example, the projected beammay be horizontal at one end and vertical at the other end.Alternatively, both may be horizontal or vertical.

It is contemplated that each arm 1122 can support two laser diodes sothat a plurality of patterns can be generated on the surface upon whichthe laser light contacts. When two laser diodes are supported on eacharm, it is desirable to provide a lens through which the light emittedfrom each diode passes. The lens may alter the beam emitted from thelaser diode so that the light projected from the housing can be in theform of + or other pattern.

The laser diodes 1130 are powered from an electrical source that may bethe same as or different from the power source used for the vacuumgenerating mechanism 50. In one embodiment, the laser diodes 1130 arepowered from a source that can be actuated at the same time the motorfor the vacuum generating mechanism 50 is actuated. In anotherembodiment, a separate switch 1050 is provided so that the laser diodes1130 can be powered while the vacuum generating mechanism 50 is notoperating. In this instance, a switch 1050 may be provided on the top ofthe laser generator housing 1034, as shown in FIG. 18. The switch 1050may have more than one position. For example, the switch 1050 may havean off position 1052, where no power is provided to the laser diodes1130. In this position, it is desirable to lock-out the self-levelingmechanism 1100 to protect the self-leveling mechanism 1100.

The switch 1050 may have a self-leveling position 1054, where theself-leveling mechanism 1100 is activated and the laser diodes 1130 arepowered. The switch 1050 may also have an angle finder position 1056, inwhich it is contemplated that, after the laser diodes 1130 have beenself-leveled, the switch can be moved to an angle finder position 1056after which the laser generator housing 1030 may be pivoted or rotatedrelative to the base 12 to a selected angle that is indicated on acompass indicator 1058 provided on the face of the switch 1050. Forexample, if the user wishes to project a line 30° from the horizontal,the base 12 may be releasably mounted to a substantially verticalsurface such as a wall and held in place by the vacuum generatingmechanism 50; then the switch 1050 may be positioned to theself-leveling position 1054 so that the projected beam projects a lineor other pattern at the “true” horizontal. The switch 1050 can then bemoved to the angle finder position 1056, in which the self-levelingmechanism 1100 is locked and the angle finder feature sets the referenceangle to 0°. The laser generator housing 1030 can then be pivoted orrotated with respect to the base 12 until the compass indicator 1058indicates the desired angular location, e.g., 30°.

Referring back to FIGS. 22-24, the self-leveling mechanism 1100 includesa rocking block seat 1140 that is connected to the laser generatorhousing 1030 so that the rocking block seat 1140 is fixed with respectto the laser generator housing 1030. The rocking block seat 1140 isshown as a plate like structure, with ends 1142 that contact the lasergenerator housing 1030 to ensure that the rocking block seat 1140 willremain stationary with respect to the laser generator housing 1030. Theends 1142 of the rocking block seat 1140 may be provided with pliable orelastic material to ensure a tight fit with the housing 1130 and at thesame time provide cushioning. Of course, any suitable shape may be usedso that the rocking block seat 1140 will provide a stationary structureto provide bearing faces 1144, as described below.

The rocking block seat 1140 has a pair of bearing faces 1144 to receivebearings 1152 formed on the ends of a bearing rocking block 1150. Thebearing rocking block 1150 is rotatably secured to the rocking blockseat 1140 by a pair of bearing straps 1170 that form a bearing face forthe bearings 1152 on the ends of the bearing rocking block 1150. Thebearing rocking block 1150 has a shaft aperture 1154 to receive one endof a shaft 1160 in a non-rotatable manner. The other end of the shaftcarries a bearing 1162 that is rotatably received in a shaft hole 1110provided on the frame 1102.

One skilled in the art will appreciate that by providing rotatablebearings that are perpendicular to each other the arms 1122 of lasergenerator, and thus, the laser diodes 1130 will be self-leveling in twodirections. The first direction allows the arms 1122 of the frame 1102to assume a horizontal position so that a horizontal beam can beprojected. In other words, the distal ends 1124, 1126 of the arms 1122can move vertically (up and down, i.e., toggle) to assume a horizontalposition. The second direction allows the arms 1122 to rotate about apivot from the front 1036 of the laser generator housing to the rear1038 of the laser generator housing. In other words, the seconddirection is perpendicular to the first direction. Of course, it isunderstood that one of the directions of self-leveling can be omitted toprovide a simpler mechanism.

Desirably, a damping mechanism 1180 is provided at the top of the frame1102 to assist the self-leveling mechanism 1100. In this regard,non-ferrous material 1182 is provided on a top portion of the frame 1102opposite a magnet 1184 so that the non-ferrous portion 1182 ismaintained at a certain distance from the magnet 1184.

Another embodiment of the self-leveling mechanism 1100 is illustrated inFIGS. 25-27. In this embodiment, a frame 1102 is provided with a dampingdome 1182, a counterweight 1106, and two arms 1122 extending outwardfrom the frame. The distal ends 1124, 1126 of the arms define a housingto carry a laser diode 1130. The frame may be a single piece or, asshown in FIG. 27 made from several pieces. In the embodiment shown inFIG. 27, the horizontal portion 1120 of the frame 1102 includes thedistal ends 1124 connected to proximal ends 1125 by a pin 1123.

The proximal ends 1125 of the arms have an aperture 1127 to receive abearing pin 1129, on which a rocking bearing 1153 is rotatably mounted.The rocking bearing 1153 a is mounted within a rocking bearing block1150 a in the form of a truncated cylinder, which in turn is mountedwithin a rocking block seat 1140 a, which is in the form of acylindrical bearing. In particular, the rocking bearing block 1150 a ismounted in the inner annulus 1141 of the rocking block seat 1140 a andmay be secured by a plate 1151. The rocking block seat 1140 a ispositioned such that the frame 1102 is capable of rotating with respectto the rocking block seat 1140 a. For instance, the rocking block seat1140 a may be held in a fixed position by or within the laser generatorhousing 1030. Because the bearing pin 1129 is connected to the frame1102 through the aperture 1127 at the proximal ends of the arms 1122,the frame 1102 is able to pivot in a first direction. At the same time,because the rocking bearing 1153 a is able to move within the rockingbearing block 1150 a, the frame 1102 is able to pivot in a seconddirection perpendicular to the first direction.

While embodiments of the invention have been illustrated and described,it is not intended that these embodiments illustrate and describe allpossible forms of the invention. Rather, the words used in thespecification are words of description rather than limitation, and it isunderstood that various changes may be made without departing from thespirit and scope of the invention.

1. A modular tool assembly comprising: a. a tool base including: i. ahousing, ii. a mounting seal extending from a portion of the housingcooperating with the mounting surface to define a vacuum pockettherebetween, iii. a vacuum generating mechanism disposed within thehousing, the vacuum generating mechanism including a pump configured toremove air from the vacuum pocket to secure the housing to the mountingsurface; and b. a modular tool attachment releasably secured to aportion of the housing of the tool base in a fixed relationship relativeto the mounting surface.
 2. The modular tool assembly of claim 1 whereinthe modular tool attachment further comprises one or more connectingarms extending from a tool attachment housing that releasably engage oneor more receiving portions formed in a guide member in the upper housingportion of the tool base to releasably secure the modular toolattachment to the tool base.
 3. The modular tool assembly wherein themodular tool attachment is rotatable with respect to the tool base. 4.The modular tool assembly of claim 1 further comprising a motor to drivethe pump and a power source electrically connected to the motor.
 5. Themodular tool assembly of claim 3 further comprising a sensor thatmonitors the vacuum pocket and activates the pump if the sensor detectsa loss of pressure in the vacuum pocket.
 6. The modular tool assembly ofclaim 1 further comprising a switch disposed on the upper housingportion of the tool base operatively connected to the vacuum generatingmechanism allowing a user to activate the vacuum generating mechanism.7. The modular tool assembly of claim 1 wherein the vacuum generatingmechanism comprises a lever operatively cooperating with a portion ofthe mounting seal wherein the lever in a first position creates a cavitybetween the attachment surface and the portion of the mounting seal. 8.The modular tool assembly of claim 1 wherein a cavity is formed in abottom surface of the lower housing portion of the tool base whichcooperates with the mounting seal and mounting surface to create thevacuum pocket.
 9. The modular tool assembly of claim 3 wherein the powersource comprises a rechargeable power source mounted within the housing.10. The modular tool assembly of claim 9 wherein the modular toolattachment comprises a laser leveling device.
 11. The modular toolassembly of claim 10 wherein the laser leveling device further comprisesa housing, a laser light source disposed within the housing operativelyconnected to a power source, the laser light source including at leastone diode, wherein an alignment beam is projected through an aperture inthe housing to denote a reference plane along the mounting surface. 12.The modular tool assembly of claim 11 wherein the laser leveling devicefurther comprises one or more bubble levels provided on the laser levelhousing.
 13. The modular tool assembly of claim 11 wherein the laserlight source is provided on a self-leveling mechanism so that thealignment beam is self-leveling.
 14. The modular tool assembly of claim13 wherein the self-leveling mechanism is in the shape of a T, with ahorizontal portion defining arms upon which the laser diodes aremounted.
 15. The modular tool assembly of claim 14 further including alens spaced from the diode and receiving light from the diode andemitting a planar beam of light, wherein the lens is rotatable withrespect to the diode to change an orientation of the planar beam oflight.
 16. The modular tool assembly of claim 13 wherein the selfleveling mechanism provides self-leveling in two directions.
 17. Amodular tool assembly comprising: a. a tool base having a lower housingportion and an upper housing portion including a guide member having oneor more receiving portions; b. a mounting seal extending from the lowerhousing portion cooperating with the mounting surface to define a vacuumpocket therebetween; c. a power source disposed within the upper housingportion; d. a vacuum generating mechanism electrically connected to thepower source and disposed within the upper housing portion, the vacuumgenerating mechanism including a motor, a pump operatively driven by themotor configured to remove air from the vacuum pocket through anaperture in the lower housing portion to secure the housing to themounting surface and a sensor mounted proximate the aperture in thelower housing portion which monitors the vacuum pocket and activates thepump if the sensor detects a loss of pressure in the vacuum pocket; e. aswitch operatively connected to the vacuum generating mechanism disposedon the upper housing portion of the tool base allowing a user toactivate the vacuum generating mechanism; and f. a modular toolattachment including a laser generator housing that includes laserdiodes contained within the housing that are self-leveling, wherein thelaser generator housing is rotatable with respect to the base in atleast one direction.
 18. The modular tool assembly of claim 17 whereinthe laser generator housing is rotatable with respect to the base in atleast two directions.